US8418784B2

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Publication number: US8418784B2
Application number: US12/777,429
Authority: US
Inventors: David R. Hall; Thomas Morris
Original assignee: Individual
Current assignee: Novatek IP LLC
Priority date: 2010-05-11
Filing date: 2010-05-11
Publication date: 2013-04-16
Also published as: US20110278072A1

Abstract

In one aspect of the invention, a drilling assembly comprises a head located on a rotational axis of the assembly and comprises at least one head element. At least one blade extends distally from the head. A plurality of blade degradation elements are rotationally supported on the blade. Each degradation element comprises an attack angle that affects the penetration rate of each degradation element and a laterally offset angle that primarily affects the rotational rate of each degradation element within their holders. The drilling assembly comprises a central cutting region. The blade degradation elements within the central cutting region form an attack angle of 15 to 20 degrees with the rotational axis of the drilling assembly.

Description

BACKGROUND OF THE INVENTION

The present invention relates to a drilling assembly, and more particularly to the central region of a drilling head assembly for boring into formations.

U.S. Pat. No. 5,366,031 to Richards, which is herein incorporated by reference for all that it contains, discloses an auger with a boring head having an arrangement for cutting relatively hard earth formations such as rock. First and second groups of drill bits are mounted to the boring head such that when the head is rotated, each bit in those groups cuts a different path at a different height to provide more than 100% coverage of the work surface being cut, while stabilizing the auger by distributing the down force of the auger over the entire bit rotation. The drill bits also are oriented to ensure bit rotation at relatively large attack angles (the angle the bit forms with the work surface there beneath) of about 50° to 60° to enhance auger penetration rates without detracting from the bit sharpening effect that results from proper bit rotation.

U.S. Pat. No. 3,821,993 to Kniff, which is herein incorporated by reference for all that it contains, discloses an auger arrangement for boring holes in earth formations in which the auger comprises a body with a central cutter arrangement including a pilot cutter on the axis and with laterally extending wing portions on the auger, on each of which is pivotally mounted a wing cutter arranged to swing outwardly when the auger rotates in cutting direction and to swing inwardly when the auger is not rotating or when it is rotating in the reverse direction so that the auger can readily be withdrawn from a hole bored thereby.

U.S. Pat. No. 3,763,942 to Levitt, which is herein incorporated by reference for all that it contains, discloses an auger or boring head, especially for horizontal rock and earth drilling having a circular ring of circumferentially spaced tool bits or teeth, a plurality of spokes or fins with leading ends carrying tool bits or cutting teeth in convex curved or arcuate contours from a central cutting point forwardly of the ring to the periphery of the ring. The cutting teeth on the ring project radially outward from the periphery thereof and are tilted forwardly in the direction of rotation of the auger head. The cutting teeth on the spokes or fins project forwardly, are tilted toward the direction of rotation of the heard and are also tilted backwardly to present the tip end of each tooth in a straight forward direction to the surface while it is cutting. In addition, the teeth are staggered so that successive teeth will not have the same cutting track. A head or socket is provided in the center of the auger head for connection to a drill rod or stem. Large open areas are provided through the ring between the spokes or fins, and the earth or rock cut by the head is free to flow through these spaces to a spiral conveyor which preferably has it leading edge behind one of the spokes or fins.

Examples of auger assembly from the prior art are disclosed in U.S. Pat. No. 2,981,403 to Goodrich, U.S. Pat. No. 2,800,302 to McCleannan, U.S. Pat. No. 4,917,196 to Stiffler, U.S. Pat. No. 5,794,727 to Murray, which are all herein incorporated by reference for all that they contain.

BRIEF SUMMARY OF THE INVENTION

In one aspect of the invention, a drilling assembly comprises a head located on a rotational axis of the assembly and comprises at least one head element. At least one blade extends distally from the head. A plurality of blade degradation elements are rotationally supported on the blade. Each degradation element comprises an attack angle that affects the penetration rate of each degradation element and a laterally offset angle that primarily affects the rotational rate of each degradation element within their holders fixed to the blade. The drilling assembly comprises a central cutting region on each blade. The blade degradation elements within the central cutting region form an angle between 15 and 20 degrees with the rotational axis of the drilling assembly.

The central cutting region may be defined within a 13 inch radius from the rotational axis of the drilling assembly. The central cutting region may also be defined within a six inch radius from the rotational axis of the drilling assembly. The attack angle may be between 16 and 18 degrees. The blade may comprise at least one degradation element. The plurality of blade degradation elements may comprise a wear resistant tip comprising a pointed sintered polycrystalline diamond compact supported on a cemented metal carbide support. The support may be bonded to a cemented metal carbide bolster at a forward diameter, which comprises a cross-sectional thickness less than or substantially equal to a largest diameter of the bolster. The support may be segmented. At least one segment of the support may be press fitted into a cavity of a body of the degradation element. The pointed diamond compact may comprise a greater axial thickness than an immediately adjacent segment of the support. The pointed diamond compact may comprise a greater axial thickness than the support. The pointed diamond compact may comprise a curvature formed in a plane substantially parallel with a central axis of the tip. The curvature may be between 0.050 and 0.110 inch radius of curvature. The assembly may be an auger assembly. The assembly may be a coring bucket assembly.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective diagram of an embodiment of a drilling assembly.

FIG. 2 is a perspective diagram of an embodiment of a drilling head assembly.

FIG. 3 is a perspective diagram of another embodiment of a drilling head assembly.

FIG. 4 is a perspective diagram of an embodiment of a plurality of blade degradation elements.

FIG. 5 is an exploded view of a diagram of an embodiment of a blade degradation element.

FIG. 6 is a cross-sectional diagram of an embodiment of a blade degradation element.

FIG. 7 is an orthogonal diagram of an embodiment of a drilling head assembly.

FIG. 8 is a cross-sectional diagram of another embodiment of a tip.

FIG. 9 is an orthogonal diagram of another embodiment of a blade degradation element.

FIG. 10 is a perspective diagram of an embodiment of a drilling assembly.

DETAILED DESCRIPTION OF THE INVENTION AND THE PREFERRED EMBODIMENT

FIG. 1 is a perspective diagram of an embodiment of a drilling assembly constructed in accordance with the present invention. In the embodiment ofFIG. 1, the drilling assembly is a auger assembly. Theauger assembly100 comprises anauger shaft101,first blade105,second blade110 and acentral cutting region120. Thefirst blade101 and thesecond blade110 are arranged in a helical position around theshaft101 to convey debris to the surface of the area being excavated. Thecentral cutting region120 includes aboring head130, first and second blade assemblies and amain head150. Theboring head130 is secured to one end of theauger shaft101, and an end portion of the first and

second blades

105,110. Themain head150 is releasably secured to theboring head130 to facilitate replacement of themain head150. In any event, theshaft101,boring head130, and themain head150 collectively share a commonrotational axis160.

Referring toFIG. 2, a 26 inch diameter (ø1), or 13 inch radius,central cutting region120 is disclosed. Both

blades

105,110 may comprise a plurality ofblade degradation elements200 attached to an edge of the

blades

105,110. The plurality ofblade degradation elements200 may comprise an attack angle (θ) of 15 to 20 degrees. The attack angle is formed between a central axis of the blade degradation element and the rotational axis of the drilling head assembly. A 15 to 20 degree angle for blade degradation elements within the central cutting region is believed to have an optimal performance when the blade degradation cutting elements are enhanced with tips of comprising sintered polycrystalline diamond. In some embodiments, the central cutting region is less than 26 inches in diameter. For example, the diameter may be closer to 12 inches. In some embodiments, the blade degradation elements may form an attack angle of 16 to 18 degrees. Preferably, the attack angle is closer to 17 degrees.

The attack angle determine penetration rate of the drilling assembly. It is believed that the blade degradation elements or the gauge degradation elements that are not within the central cutting region should have attack angles greater than 20 degrees.

Prior art references, such as U.S. Pat. No. 5,366,031 to Richards, teaches the attack angles of all the degradation elements, not just the degradations elements secured close to the rotational axis of the drilling assembly, should form an angle of 30 to 40 degrees. See column 7, lines 6-10. (However, note that Richard's attack angle is defined with reference to a horizontal, while the present invention is defined with reference to the rotational axis of the drilling assembly. The present invention's attack angle is more closely aligned to the Richard's ζ angle, line 9).

FIG. 3 discloses a drilling head assembly with an overall diameter that is just over the central cutting region's diameter. In this embodiment, the majority of the blade degradation elements will form an angle of 15 to 20 degrees. Here, only the gauge degradation elements form an angle greater than 20 degrees.

FIG. 4 discloses an embodiment ofblade degradation elements200 attached to eitherfirst blade105 orsecond blade110. The attack angle (θ) of each of thedegradation elements200 may be between 15 and 20 degrees, which allows greater penetration rates, and thus faster boring rates. The attack angle (θ) is defined as the angle formed between thevertical axis401 of aformation400 and arotational axis410 of thedegradation element200.

FIG. 5 discloses an exploded view of an embodiment of ablade degradation element200. Thedegradation element200 may comprise a wearresistant tip260 comprising a pointed sintered polycrystalline diamond compact420 supported on a cementedmetal carbide support430. Thecarbide support430 may be segmented. At least one segment of thesupport430 may be press fit into acavity450 of a body of thedegradation element200. In some embodiments, thedegradation element200 may comprise a braze joint. Thesupport430 may be bonded to a cemented metal carbide bolster460 at a forward diameter, which comprises a cross-sectional thickness less than or substantially equal to a largest diameter of the bolster460. The bolster460 may comprise cemented metal carbide, a steel matrix material, or other material and may be press fit or brazed to a drill bit body. The pointed diamond compact420 may comprise a greater axial thickness than an immediately adjacent segment of thesupport430. Such composition of thetip260 of thedegradation element200 may increase the longevity of thedegradation elements200. In some embodiments, the pointed diamond compact260 may comprise a greater axial thickness than thesupport430.

Referring toFIG. 6, thedegradation element200 may be attached to aholder650 mounted on the

blades

105,110. Eachdegradation element200 induces a load into theformation400, which in turn imposes a reaction force on the pick. The reaction forces may depend on WOB, rpm, formation type, torque, or combinations thereof. In some embodiments, a balance between penetration rate and lifespan of theblade degradation element200 may be obtained when a resultant force vector aligns with anaxis410 of thedegradation element200. The fractures may propagate in theformation400, resulting in a removal ofchips600 offormation400.

Referring toFIG. 7, a bottom view of an embodiment of anauger assembly100 is shown. Thedegradation elements200 may rotate while following a helical path. Eachdegradation element200 may follow a separate helical path as theauger assembly100 drills deeper into a formation. Eachdegradation element200 may comprise a laterally offset angle (β), which imposes a lateral force on the pick adapted to cause the pick to rotate. If therotational axis410 of thedegradation element200 is tangent to the helical cutting path, the offset angle (β) is generally zero. Thedegradation elements200 may continue to rotate in their holders (not shown) for a wide range of offset angle (β).

Referring toFIG. 8, thedegradation element200 may comprise a sintered polycrystalline diamond compact420 bonded to a cementedmetal carbide substrate830 at anon-planar interface840. Thedegradation element200 may comprise a substantially pointedgeometry850 and an apex860. The apex860 may comprise acurvature870 formed in a plane substantially parallel with a central axis of thetip410. Thecurvature870 may be between 0.050 and 0.110 inch radius of curvature. In some embodiments, thecurvature870 may comprise a variable radius of curvature, a portion of a parabola, a portion of a hyperbola, a portion of a catenary, or a parametric spline. An includedangle880 is formed by the walls of thepointed geometry850. In some embodiments, the includedangle880 may be between 75 degrees and 90 degrees.Non-planar interface840 may comprise an elevated flattedregion890 that connects to a cylindrical portion of thesubstrate830 by atapered section895. In some embodiments, the diamond compact420 may comprise a volume with less than 5 percent catalyst metal concentration, while 95 percent of the interstices in the sintered polycrystalline diamond comprise a catalyst.

FIG. 9 discloses an embodiment of ablade degradation element990 which may be used in machines in mining, asphalt milling, or trenching industries. Theelement990 may be used inauger assembly100. Theelement990 may comprise ashank900 and abody910, thebody910 being divided into first andsecond segments920 &930. Theshank900 may be adapted to be attached to a driving mechanism. Aprotective spring sleeve940 may be disposed around theshank900 both for protection and to allow thedegradation element990 to be press fit into the holder (not shown) while still being able to rotate. Awasher950 may be disposed around theshank900 such that when theelement990 is inserted into the holder, thewasher950 protects an upper surface of the holder and also facilitates rotation of theelement990. Thewasher950 andsleeve940 may be advantageous since they may protect the holder which may be costly to replace.

The wearresistant tips260 may comprise a pointed sintered polycrystalline diamond compact supported on a cemented metal carbide support. Chemical vapor deposition (CVD) technique may be used and may provide precise shapes, but it may not provide as strong bonding between diamond crystals. Preferably, sintered diamond is used, which is subjected to high temperature and high pressure resulting in strong bonds between diamond crystals. Natural diamonds may also be used.

FIG. 10 discloses that the present invention may be incorporated into acoring bucket assembly1000 as well as other drilling assemblies. Theassembly1000 may comprise a plurality ofdegradation elements200 at one end disposed in a particular order as well as particular orientation as shown in the figure. Theassembly1000 may be used to drill through clay, soft soil, hard rock, or combinations thereof.

In some embodiments of the invention, the picks are rigidly fixed within the holders such that there is no rotation. In some embodiments, the picks are allowed to rotate, but the assembly comprises a mechanism that restricts free rotation causing the picks to rotate slower. This may be advantageous by reducing the wear between the shank of the pick and the inner bore of the holder.

Whereas the present invention has been described in particular relation to the drawings attached hereto, it should be understood that other and further modifications apart from those shown or suggested herein, may be made within the scope and spirit of the present invention.

Claims

What is claimed is:

1. A drilling assembly, comprising:

a head located on a rotational axis of the assembly;

at least one blade extending distally from the head;

a plurality of blade degradation elements being rotationally supported on the blade;

each degradation element comprising an attack angle formed between a central axis of the degradation element and the rotational axis of the assembly that affects the penetration rate of each degradation element and a laterally offset angle formed between the central axis of the degradation element and a line tangent to a helical cutting path of the degradation element that primarily affects the rotational rate of each degradation element within their holders fixed to the blade;

wherein the plurality of blade degradation elements comprise a wear resistant tip comprising a pointed sintered polycrystalline diamond compact supported on a cemented metal carbide support; and

a central cutting region of each blade;

wherein the attack angle of each blade degradation element within the central cutting region is between 15 and 20 degrees.

2. The assembly ofclaim 1, wherein the central cutting region is defined within a 13 inch radius from the rotational axis of the drilling assembly.

3. The assembly ofclaim 1, wherein the central cutting region is defined within a six inch radius from the rotational axis of the drilling assembly.

4. The assembly ofclaim 3, wherein the attack angle is 16 to 18 degrees.

5. The assembly ofclaim 1, wherein the blade comprises at least one degradation element.

6. The assembly ofclaim 1, wherein the cemented metal carbide support is bonded to a cemented metal carbide bolster at a forward diameter, which comprises a cross sectional thickness less than or substantially equal to a largest diameter of the bolster.

7. The assembly ofclaim 1, wherein the cemented metal carbide support is segmented.

8. The assembly ofclaim 7, wherein at least one segment of the cemented metal carbide support is press fit into a cavity of a body of the degradation element.

9. The assembly ofclaim 7, wherein the pointed diamond compact comprises a greater axial thickness than an immediately adjacent segment of the cemented metal carbide support.

10. The assembly ofclaim 1, wherein the pointed diamond compact comprises a greater axial thickness than the cemented metal carbide support.

11. The assembly ofclaim 1, wherein the pointed diamond compact comprises a curvature formed in a plane substantially parallel with a central axis of the tip.

12. The assembly ofclaim 11, wherein the curvature is between 0.050 and 0.110 inch radius of curvature.

13. The assembly ofclaim 1, wherein the assembly is an auger assembly.

14. A drilling assembly, comprising:

a head located on a rotational axis of the assembly;

at least one blade extending distally from the head;

each degradation element comprising an attack angle formed between a central axis of the degradation element and the rotational axis of the assembly that affects the penetration rate of each degradation element;

a central cutting region of each blade;